CN115009250A - Brake pad wear detection method and system for rail vehicle electromechanical braking system - Google Patents
Brake pad wear detection method and system for rail vehicle electromechanical braking system Download PDFInfo
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- CN115009250A CN115009250A CN202210747835.8A CN202210747835A CN115009250A CN 115009250 A CN115009250 A CN 115009250A CN 202210747835 A CN202210747835 A CN 202210747835A CN 115009250 A CN115009250 A CN 115009250A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60T—VEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
- B60T17/00—Component parts, details, or accessories of power brake systems not covered by groups B60T8/00, B60T13/00 or B60T15/00, or presenting other characteristic features
- B60T17/18—Safety devices; Monitoring
- B60T17/22—Devices for monitoring or checking brake systems; Signal devices
- B60T17/228—Devices for monitoring or checking brake systems; Signal devices for railway vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60T—VEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
- B60T1/00—Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles
- B60T1/02—Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels
- B60T1/06—Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels acting otherwise than on tread, e.g. employing rim, drum, disc, or transmission or on double wheels
- B60T1/065—Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels acting otherwise than on tread, e.g. employing rim, drum, disc, or transmission or on double wheels employing disc
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D66/00—Arrangements for monitoring working conditions, e.g. wear, temperature
- F16D66/02—Apparatus for indicating wear
- F16D66/021—Apparatus for indicating wear using electrical detection or indication means
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- General Engineering & Computer Science (AREA)
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Abstract
The invention provides a brake pad wear detection method and system for an electromechanical braking system of a railway vehicle. After a new brake pad is replaced, starting a motor from an initial zero position, driving a clamp to move towards a brake application direction until the motor is locked, recording the number of turns of the motor at the moment, the stroke of the clamp, and the movement time from the motor starting to the motor locking; after the brake system works for a period of time, starting from a locked-rotor position of a relieving direction, starting the motor, driving the clamp to move towards a brake applying direction until the motor is locked, recording the number of turns of the motor at the moment, the stroke of the clamp, and the movement time from the motor starting to the motor locking; calculating a difference value of the number of rotation turns, a difference value of the clamp stroke and a difference value of the movement time; and if the difference value of the number of rotating turns exceeds a set threshold value of the number of turns, or the difference value of the stroke of the clamp exceeds a set threshold value of the stroke difference, or the difference value of the movement time exceeds a set threshold value of the time difference, judging that the brake pad needs to be replaced. The method and the system can realize intelligent automatic monitoring of the brake pad abrasion condition.
Description
Technical Field
The invention relates to the technical field of train braking, in particular to a brake pad abrasion detection method and system of an electronic mechanical braking system of a railway vehicle.
Background
The friction braking modes commonly used by rail vehicles are air braking and hydraulic braking, and different pressures are applied to a brake disc by pushing a clamp through controlling the pressure of compressed air or hydraulic oil so as to achieve the purpose of realizing different braking forces.
As a novel braking technology, electromechanical braking adopts a motor as a power source, and the clamp is pushed to apply different pressures to a brake disc through the transmission (a lead screw and the like) of a mechanical mechanism (a basic braking device).
The electronic mechanical brake system is provided with a brake pad on a clamp, and when a brake force is applied, the brake pad is contacted with a brake disc to generate a friction force to brake a train. The brake lining is made of relatively soft material and can be worn when being rubbed. After a period of use, the brake lining needs to be replaced after being worn to a certain degree, otherwise, the braking effect is influenced.
The brake lining is replaced by manual visual inspection or periodically. If can the on-line monitoring brake lining wearing and tearing condition, for changing the brake lining provides the basis, will help realizing braking system's intelligent maintenance. In the prior art, an automatic monitoring system for brake pad wear is also provided, and image analysis and a monitoring mode of a displacement sensor are mostly adopted.
For example:
CN201911283954.7 discloses a method and a system for detecting a brake pad wear failure, which collects a brake pad image, performs binarization processing, and determines whether the brake pad is worn by a method of calculating a connected domain.
CN201811256672.3 discloses a basic brake on-line detector and an intelligent detection method, wherein a connecting rod is adopted to form a magnetostrictive displacement sensor which is arranged in a connecting pipe inside a brake unit, and a magnetic ring is matched with the displacement sensor to perform positioning detection on a brake pad.
The processing procedure of the graphic processing method is complex, and the detection function of the sensor detection method is single.
Disclosure of Invention
The present invention is directed to solve one of the above problems, and provides an intelligent brake pad detection method and system, which can automatically detect the degree of wear of the brake pad.
In order to realize the purpose, the invention adopts the technical scheme that:
a brake pad wear detection method of a rail vehicle electromechanical braking system comprises the following steps:
an initialization step: after a new brake pad is replaced, starting the motor, driving the clamp to move towards the brake relieving direction until the motor stalls, recording the movement position of the motor at the moment, and taking the corresponding number of turns as a zero point;
a calibration step: starting a motor, driving a clamp to move towards a brake application direction until the motor is locked, recording the number of turns of the motor at the moment, converting the number of turns of the motor into the stroke of the brake clamp, and recording the movement time from the starting of the motor to the locking of the motor;
a detection step: after the brake system works for a period of time, starting from a locked-rotor position of a relieving direction, starting the motor, driving the clamp to move towards a brake applying direction until the motor is locked, recording the number of rotation turns of the motor at the moment, converting the number of the rotation turns of the motor into a stroke of the brake clamp, and recording the movement time from the start of the motor to the locked-rotor of the motor;
calculating a difference value of the number of rotation turns, a difference value of the clamp stroke and a difference value of the movement time;
if the difference of the rotating turns exceeds the set threshold of the turn difference,
or the clamp stroke difference value exceeds the set stroke difference threshold value,
or, the movement time difference value exceeds the set time difference threshold value,
it is determined that the brake pad needs to be replaced.
In one embodiment of the present invention, the method further comprises the following steps:
detecting the ambient temperature in the calibration step and the ambient temperature in the detection step;
calculating the influence factor of the temperature on the movement stroke:
ΔF＝g(T2)-g(T1)
and when calculating the difference value of the clamp stroke, considering the influence factor of the temperature on the movement stroke.
In one embodiment of the present invention, the method further comprises the following steps:
classifying the difference value of the number of turns of rotation based on the size of the difference value of the number of turns of rotation;
grading the clamp stroke difference values based on the sizes of the clamp stroke difference values;
grading the motion time difference value based on the size of the motion time difference value;
and generating different levels of early warning signals based on different rotation turn number difference levels, or different clamp stroke difference levels, or different movement time difference levels.
In one embodiment of the present invention, the method further comprises the following steps:
setting a wear speed threshold;
and monitoring the wear speed of the brake pad of the whole vehicle, and if the wear speed of a brake pad is greater than a wear speed threshold value, judging that the brake pad is abnormal in wear.
In one embodiment of the present invention, the method further comprises the following steps:
setting a wear speed difference threshold;
monitoring the wear speed of the brake pads of the whole vehicle, and comparing the wear speed difference of the brake pads;
and if the difference value between the wear speed of a certain brake pad and the average wear speed of other brake pads is greater than the wear speed difference value threshold value, judging that the brake pad is abnormal in wear.
An embodiment of the present invention further provides a brake pad wear detection system for a railway vehicle electromechanical braking system, including:
a motor control unit: the motor is controlled to rotate so as to drive the clamp to move;
a counting unit: the motor is used for recording the number of turns of the motor;
a stroke calculation unit: the clamp moving distance is calculated based on the number of rotation turns of the motor;
a timing unit: the motor control device is used for recording the movement time when the motor runs to a specified position;
a calibration data calculation unit: the brake disc is used for recording the number of turns of the motor, the stroke of the brake clamp and the movement time of the motor locked rotor when the clamp moves to the locked rotor position of the motor along the brake applying direction from the locked rotor position in the relieving direction after a new brake pad is replaced;
a detection data calculation unit: the device is used for recording the number of turns of the motor, the stroke of the braking clamp and the movement time of the motor locked rotor when the clamp starts to move to the locked rotor position of the motor along the braking application direction from the locked rotor position of the relieving direction after the braking system works for a period of time; and generating a brake pad fault detection signal based on the calculated value and the calculated difference value recorded by the calibration data calculating unit.
In one embodiment of the present invention, the wear detection system further comprises:
a temperature acquisition unit: the temperature sensor is used for detecting the ambient temperature in the calibration step and the ambient temperature in the detection step;
a temperature factor calculation unit: the device is used for calculating the influence factor of the temperature on the movement stroke;
the detection data calculation unit corrects the brake caliper stroke based on the temperature influence factor.
In one embodiment of the present invention, the wear detection system further comprises:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp in the braking process and the time generated by the change;
the abrasion speed calculation unit monitors the abrasion speed of the brake pad of the whole vehicle, and if the abrasion speed of a brake pad is greater than an abrasion speed threshold value, the brake pad is judged to be abraded abnormally.
In one embodiment of the present invention, the wear detection system further comprises:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp and the time generated by the change in the braking process, and calculating the abrasion speed difference of each brake pad;
the abrasion speed calculation unit monitors the abrasion speed of the brake pad of the whole vehicle, and if the difference value between the abrasion speed of a brake pad and the average abrasion speed of other brake pads is larger than the abrasion speed difference value threshold value, the abrasion abnormality of the brake pad is judged.
The rail vehicle electronic mechanical brake system brake pad abrasion detection method provided by the invention has the beneficial effects that:
the method is realized by the automatic control of an electronic mechanical brake system: when a new brake pad is replaced, the electromechanical brake system mechanism is controlled to move through a detection command, the movement stroke of the electromechanical brake system mechanism is calculated, and the movement stroke is recorded as a brake pad zero-wear parameter. When the brake pad is used daily, the movement of the control mechanism is also controlled through a detection command, and the movement stroke of the control mechanism is calculated to serve as a real-time brake pad wear parameter. And determining whether to give out a prompt for replacing the brake pad or not according to whether the difference value between the zero wear parameter and the real-time wear parameter exceeds a preset wear limit value for replacing the brake pad or not.
The method provided by the invention can calculate the abrasion speed of the brake pad and analyze whether the brake pad is normal or not according to the abrasion speed; and the wear conditions of the brake pads are statistically analyzed, the brake pad states are judged, the service lives of the brake pads are predicted, the maintenance cost is reduced, and the like.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise.
FIG. 1 is a schematic diagram of the electromechanical brake system.
FIG. 2 is a schematic diagram of a brake application architecture for an electromechanical brake system.
FIG. 3 is a flow chart of a method for detecting wear of a brake pad according to an embodiment.
FIG. 4 is a flow chart of a method for detecting wear of a brake pad according to an embodiment.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects to be solved by the present invention more clearly apparent, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the invention.
A brake pad abrasion detection method of an electromechanical braking system of a railway vehicle is used for on-line monitoring of brake pads of the electromechanical braking system and timely monitoring brake pad faults.
The composition and the action principle of the electromechanical brake system will be described first, with reference to fig. 1 and 2.
The brake controller (EBCU) sends a brake force instruction (the magnitude of a brake force and a force value, relief and the like) to the motor controller, the motor controller controls the motor to rotate, and then the transmission mechanism drives the clamp (a brake pad is arranged on one side of the clamp close to the brake disc) to apply pressure to the brake disc or relieve the pressure.
Generally, a pressure sensor for detecting actual pressure is arranged in a transmission mechanism, and closed-loop control is performed through an actual measurement pressure value and a target braking force value, so that the actual pressure value approaches the target braking force value finally.
The transmission mechanism may be, but is not limited to, composed of a speed reduction mechanism, a lead screw nut, a clamp, and the like. The motor drives the screw nut to rotate through the speed reducing mechanism, the screw cannot rotate due to a limiting measure, and the rotary motion of the nut is converted into the linear motion of the screw. The lead screw drives the clamp to move towards the brake applying direction to apply pressure to the brake disc, or move towards the brake relieving direction to relieve. When the braking is relieved, the screw rod can finally prop against the limiting mechanism at the rear end; when the brake is applied, the lead screw moves towards the brake application direction, the brake pad is finally pressed against the brake disc, and the reaction force enables the lead screw nut to be pressed against the limiting mechanism.
The brake pad wear detection method comprises the following steps.
An initialization step: after a new brake pad is replaced, starting the motor, driving the clamp to move towards a brake relieving direction until the motor stalls, recording the movement position of the motor at the moment, and taking the corresponding number of rotation turns as a zero point; this step is performed before the brake lining is replaced with a new brake lining and put into use.
Specifically, the electronic mechanical brake motor controller receives a detection command of a vehicle brake controller (EBCU), controls the motor to rotate by a fixed torque (or fixed current/voltage), and then drives the clamp (and the brake pad) to move towards a brake release direction through the transmission mechanism until the motor is completely locked (related parts in the transmission mechanism are jacked onto the limiting mechanism). The movement position at this time was recorded as zero point (the number of motor rotations was recorded as 0).
A calibration step: starting a motor, driving a clamp to move towards a brake application direction until the motor is locked, recording the number of turns of the motor at the moment, converting the number of turns of the motor into the stroke of the brake clamp, and recording the movement time from the starting of the motor to the locking of the motor; the purpose of the calibration step is to obtain a standard value for the brake pad fault determination, which reflects the relevant parameters of the new brake pad in the state of not generating any wear, and store the relevant parameters.
Specifically, the motor is controlled to rotate by a fixed torque (or a fixed current/voltage), and then the clamp (and the brake pad) is driven by the transmission mechanism to move towards the brake application direction until the motor is completely locked (the clamp is pressed on the brake disc). The number of turns the motor has made at this time is recorded. Calculating the movement stroke l according to the transmission relation l (f) (n) between the number of turns n of the motor and the movement stroke l of the clamp 1 . (for example, in the case of a reduction mechanism + screw, the reduction ratio i of the reduction mechanism, the lead p of the screw, and the number of revolutions n of the motor 1 Calculating l 1 ＝p*n 1 I). Storage l 1 And the detection time, which can also be the number n of turns of the motor 1 And a detection time, or a motor movement time and a detection time.
A detection step: after the brake system works for a period of time, starting from a locked-rotor position of a relieving direction, starting the motor, driving the clamp to move towards the brake applying direction until the motor is locked-rotor, recording the number of rotation turns of the motor at the moment, and converting the number of the rotation turns of the motor into the stroke l of the brake clamp 2 Recording the movement time from the starting of the motor to the locked rotor of the motor; the brake pads will wear after a period of operation of the braking system, and thisWear may be manifested in a variety of parameter indicators, such as, for example, wear on the brake pads, more turns of the motor required to achieve braking in place, or longer distance of movement of the tongs required, or longer time to achieve braking in place.
Specifically, the EBCU sends a detection command to the motor controller as needed (e.g., before the train leaves the warehouse, after the train enters the warehouse, or at a fixed time every day). And the motor controller repeats the control actions of the initialization step → the calibration step during calibration and calculates the detection data.
Calculating the distance l 2 And l 1 Is equal to 2 -l 1 This is the real-time wear of the brake lining and stores this information (for example, the wear Δ l and the detection time; or the travel l can be stored) 2 And a detection time; also can be the number of turns n of the motor 2 And detection time, or motor movement time and detection time).
Calculating a difference value of the number of rotation turns, a difference value of the clamp stroke and a difference value of the movement time;
if the difference of the rotating turns exceeds the set threshold of the turn difference,
or the clamp stroke difference value exceeds the set stroke difference threshold value,
or, the movement time difference value exceeds the set time difference threshold value,
it is determined that the brake pad needs to be replaced. In the fault determination process, a parameter may be selected, for example: if delta l reaches the specified requirement of the abrasion loss limit value of the brake pad to be replaced, the brake pad is prompted to be replaced.
In an embodiment of the present invention, the method further comprises the following steps:
detecting the ambient temperature in the calibration step and the ambient temperature in the detection step;
calculating the influence factor of the temperature on the movement stroke:
ΔF＝g(T 2 )-g(T 1 )；
and when calculating the difference value of the clamp stroke, considering the influence factor of the temperature on the movement stroke. Wherein Δ F represents the temperature T 2 And T 1 Difference in mechanical deformation of the pliers, g (T2) at temperature T 2 The amount of mechanical deformation of the clamp at a certain reference temperature (which may be 0 ℃ C., for example); g (T1) represents the temperature T 1 The amount of mechanical deformation of the clamp relative to a reference temperature (which may be 0 ℃ C., for example).
Specifically, temperature considerations are taken into account. The deformation of the material used in the transmission mechanism under the action of force is influenced by the change of temperature, and the relation of the deformation influenced by temperature is expressed as F ═ g (T). In the first measurement after replacement of a new brake pad, the temperature T at that time is recorded 1 (ii) a In daily measurements, the real-time temperature T is detected 2 When calculating the difference Δ l, Δ F is equal to g (T) 2 )-g(T 1 ) Taking into account Δ l ═ l 2 -l 1 - Δ F. Preferably, the temperature information during measurement is also stored in the information, so that the brake lining wear information can be conveniently calculated in the subsequent step.
In one embodiment of the present invention, the method further comprises the following steps:
classifying the difference value of the number of turns of rotation based on the size of the difference value of the number of turns of rotation;
grading the clamp stroke difference values based on the sizes of the clamp stroke difference values;
grading the motion time difference value based on the size of the motion time difference value;
and generating different levels of early warning signals based on different rotation turn number difference levels, or different clamp stroke difference levels, or different movement time difference levels. The different grades correspond to different warning signals, for example, the brake pad needs to be replaced or the warning is replaced.
In one embodiment of the present invention, the method further comprises the following steps:
setting a wear speed threshold;
and monitoring the wear speed of the brake pad of the whole vehicle, and if the wear speed of a brake pad is greater than a wear speed threshold value, judging that the brake pad is abnormal in wear.
In an embodiment of the present invention, the method further comprises the following steps:
setting a wear speed difference threshold;
monitoring the wear speed of the brake pads of the whole vehicle, and comparing the wear speed difference of the brake pads;
and if the difference value between the wear speed of a certain brake pad and the average wear speed of other brake pads is greater than the wear speed difference value threshold value, judging that the brake pad is abnormal in wear. The service life, the maintenance cost and the like of the brake pad are predicted by statistically analyzing the wear speed of the brake pad.
An embodiment of the present invention further provides a brake pad wear detection system for a railway vehicle electromechanical braking system, including:
a motor control unit: the motor is controlled to rotate so as to drive the clamp to move;
a counting unit: the motor is used for recording the number of turns of the motor;
a stroke calculation unit: the clamp moving distance is calculated based on the number of rotation turns of the motor;
a timing unit: the motor is used for recording the movement time when the motor runs to a specified position;
calibration data calculation unit: the brake disc is used for recording the number of turns of the motor, the stroke of the brake clamp and the movement time of the motor locked rotor when the clamp moves to the locked rotor position of the motor along the brake applying direction from the locked rotor position in the relieving direction after a new brake pad is replaced;
a detection data calculation unit: the motor locked-rotor monitoring system is used for recording the number of turns of the motor, the stroke of the braking clamp and the movement time of motor locked-rotor when the clamp moves to the locked-rotor position of the motor along the braking application direction from the locked-rotor position in the relieving direction after the system works for a period of time; and generating a brake pad fault detection signal based on the calculated value and the calculated difference value recorded by the calibration data calculating unit.
In one embodiment of the present invention, the wear detection system further comprises:
a temperature acquisition unit: the temperature sensor is used for detecting the ambient temperature in the calibration step and the ambient temperature in the detection step;
a temperature factor calculation unit: the device is used for calculating the influence factor of the temperature on the movement stroke;
the detection data calculation unit corrects the brake caliper stroke based on the temperature influence factor.
In one embodiment of the present invention, the wear detection system further comprises:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp and the time generated by the change in the braking process;
the wear speed calculation unit monitors the wear speed of the brake pad of the whole vehicle, and if the wear speed of a brake pad is greater than a wear speed threshold value, the brake pad is judged to be abnormal in wear.
In one embodiment of the present invention, the wear detection system further comprises:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp and the time generated by the change in the braking process, and calculating the abrasion speed difference of each brake pad;
the abrasion speed calculation unit monitors the abrasion speed of the brake pad of the whole vehicle, and if the abrasion speed ratio of the abrasion speed of a brake pad to any one of the other brake pads is greater than the abrasion speed difference threshold value, the abrasion abnormality of the brake pad is judged.
The following describes the process of the present invention with reference to specific examples.
The lead screw of the basic brake device is 10mm, and the reduction ratio is 10. The prompt information is divided into two stages: the brake lining replacement abrasion loss is 5mm, and the early warning prompt abrasion loss is 4 mm.
After the brake pad is replaced, the EBCU sends a detection command to the motor controller, and the controller controls the motor to operate with a fixed torque; the motor rotates for 28 circles from the position where the direction of the motor is blocked and is relieved by braking to the position where the direction of the motor is blocked and is applied by braking, and the stroke l is obtained by calculation 1 Is 28 mm. The motor controller records this 28mm as a parameter of zero brake pad wear.
After the train is powered on every day, the EBCU sends a brake pad abrasion detection command to the motor controller once, and the controller controls the motor to operate with fixed torque to execute detection action. (1) If the number of turns of the motor is 30.5 turns, calculating the current stroke l 2 30.5mm, the brake lining abrasion loss is 2.5 mm; the motor controller sends a message to the EBCU that the brake lining wear is within a normal range. (2) If the number of turns of the motor is 32.5 turns, calculating the current stroke l 2 32.5mm, and the brake lining abrasion loss is 4.5mm, then the motor controlAnd the controller sends brake lining wear early warning prompt information to the EBCU. (3) If the number of turns of the motor is 33.2 turns, calculating the current stroke l 2 And if the brake lining wear loss is 33.2mm and the brake lining wear loss is 5.2mm, the motor controller sends a brake lining replacement prompt message to the EBCU.
Influence of temperature on the mechanical deformation of the transmission: the temperature was 10 ℃ at the time of the initial measurement, and the mechanical deformation amount was 0.2 mm. The temperature of one measurement in daily detection is 30 ℃, and the mechanical deformation is 0.5 mm. If as in the case of (3) above, the actual wear amount of the brake pad is:
Δl＝l 2 -l 1 -ΔF＝33.2-28-(0.5-0.2)＝4.9mm
at this time, the warning message is sent out instead of the replacement message.
When the abrasion speed is higher than 1 mm/month, the brake pad is prompted to be overhauled. For example, if the wear amount detected in 5 days after 8 months is 2.2mm, the wear amount detected in one month before (5 days after 7 months) is 1.0mm, and the wear amount detected in one month is 1.2mm, the brake pad is considered to be worn too fast, and prompt information for repairing the brake pad is sent.
And counting the brake pad abrasion speed of a train. The train comprises 24 brake pads, wherein the wear speed of 23 brake pads is concentrated between 0.2 mm/month and 0.4 mm/month, the wear speed of only one brake pad is 0.8 mm/month, although the wear speed of the single brake pad does not reach the maintenance limit value, the wear speed of the single brake pad is obviously higher than the wear speed of other brake pads of the train, and the maintenance of the brake pad is also prompted.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (9)
1. A rail vehicle electronic mechanical brake system brake pad wear detection method is characterized by comprising the following steps:
an initialization step: after a new brake pad is replaced, starting the motor, driving the clamp to move towards the brake relieving direction until the motor stalls, recording the movement position of the motor at the moment, and taking the corresponding number of turns as a zero point;
a calibration step: starting upThe motor drives the clamp to move towards the brake applying direction until the motor is locked, and the number n of turns of the motor at the moment is recorded 1 Converting the number of turns of the motor into the stroke l of the brake clamp 1 And recording the movement time t from the starting of the motor to the locked rotation of the motor 1 ；
A detection step: after the brake system works for a period of time, starting from a locked-rotor position of a relieving direction, starting the motor, driving the clamp to apply directional motion to the brake until the motor is locked-rotor, and recording the number n of rotating turns of the motor at the moment 2 Converting the number of turns of the motor into the stroke l of the brake clamp 2 And recording the movement time t from the starting of the motor to the locked rotation of the motor 2 ；
Calculating a difference value of the number of rotation turns, a difference value of the clamp stroke and a difference value of the movement time;
if the difference of the rotating turns exceeds the set threshold of the turn difference,
or the clamp stroke difference value exceeds the set stroke difference threshold value,
or, the movement time difference value exceeds the set time difference threshold value,
it is determined that the brake pad needs to be replaced.
2. The method of detecting brake pad wear of a railway vehicle electromechanical brake system as claimed in claim 1, further comprising the steps of:
detecting the ambient temperature T at the calibration step 1 And the ambient temperature T at the detecting step 2 ；
Calculating the influence factor of the temperature on the movement stroke:
and when calculating the difference value of the clamp stroke, considering the influence factor of the temperature on the movement stroke.
3. The method of detecting brake pad wear of a railway vehicle electromechanical brake system as claimed in claim 1, further comprising the steps of:
classifying the difference value of the number of turns of rotation based on the size of the difference value of the number of turns of rotation;
grading the clamp stroke difference values based on the sizes of the clamp stroke difference values;
grading the motion time difference value based on the size of the motion time difference value;
and generating different levels of early warning signals based on different rotation turn number difference levels, or different clamp stroke difference levels, or different movement time difference levels.
4. The method of detecting brake pad wear of a railway vehicle electromechanical brake system as claimed in claim 1, further comprising the steps of:
setting a wear speed threshold;
and monitoring the wear speed of the brake pad of the whole vehicle, and if the wear speed of a brake pad is greater than a wear speed threshold value, judging that the brake pad is abnormal in wear.
5. The method of detecting brake pad wear of a railway vehicle electromechanical brake system as claimed in claim 1, further comprising the steps of:
setting a wear speed difference threshold;
monitoring the wear speed of the brake pads of the whole vehicle, and comparing the wear speed difference of the brake pads;
and if the difference value between the wear speed of a certain brake pad and the average wear speed of other brake pads is greater than the wear speed difference value threshold value, judging that the brake pad is abnormal in wear.
6. A rail vehicle electromechanical braking system brake pad wear detection system, comprising:
a motor control unit: the motor is controlled to rotate so as to drive the clamp to move;
a counting unit: the motor is used for recording the number of turns of the motor;
a stroke calculation unit: the clamp moving distance is calculated based on the number of rotation turns of the motor;
a timing unit: the motor is used for recording the movement time when the motor runs to a specified position;
a calibration data calculation unit: for recording the locked-rotor position of the clamp in the relieving direction after the replacement of a new brake padWhen the brake applying direction moves to the motor locked-rotor position, the number of the rotating turns of the motor is n 1 Braking clamp travel l 1 Time of movement t of motor stalling 1 ；
A detection data calculation unit: the motor rotation number n is used for recording the rotation number of the motor when the clamp starts to move to the motor locked-rotor position along the brake applying direction from the locked-rotor position in the relieving direction after the brake system works for a period of time 2 Braking clamp travel l 2 Time of movement t of motor stalling 2 (ii) a And generating a brake pad fault detection signal based on the calculated value and the calculated difference value recorded by the calibration data calculating unit.
7. The rail vehicle electromechanical brake system brake pad wear detection system of claim 6, further comprising:
a temperature acquisition unit: for detecting the ambient temperature T during the calibration step 1 And the ambient temperature T at the detecting step 2 ；
A temperature factor calculation unit: the device is used for calculating the influence factor of the temperature on the movement stroke;
the detection data calculation unit corrects the brake clamp stroke l based on the temperature influence factor 2 。
8. The rail vehicle electromechanical brake system brake pad wear detection system of claim 6, further comprising:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp in the braking process and the time generated by the change;
the wear speed calculation unit monitors the wear speed of the brake pad of the whole vehicle, and if the wear speed of a brake pad is greater than a wear speed threshold value, the brake pad is judged to be abnormal in wear.
9. The rail vehicle electromechanical brake system brake pad wear detection system of claim 6, further comprising:
wear rate calculation unit: calculating the brake pad abrasion speed based on the stroke change of the brake clamp and the time generated by the change in the braking process, and calculating the abrasion speed difference of each brake pad;
the abrasion speed calculation unit monitors the abrasion speed of the brake pad of the whole vehicle, and if the difference value between the abrasion speed of a brake pad and the average abrasion speed of other brake pads is larger than the abrasion speed difference value threshold value, the abrasion abnormality of the brake pad is judged.
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| CN116392259A (en) * | 2023-04-28 | 2023-07-07 | 极限人工智能有限公司 | Stroke and anti-collision monitoring method and system of co-track double-drive module and robot |
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